Update:
Bolts, pistons/cylinders on. Blasting parts.

http://i132.photobucket.com/albums/q...4062008032.jpg

http://i132.photobucket.com/albums/q...6072008044.jpg

http://i132.photobucket.com/albums/q...3072008035.jpg

HI Otto
just make shure you have all the blasting material out of the parts and for the engine's sake do not blast the cam carriers,
You will have to take off the intergear cover again to check the chain alignment ??

regards mike

Hi there..!
Yeah, I'm aware. My highest priority at the moment, is making sure everything is clean...!
My cam housing was cleaned at a shop.

Small update:
Finally connected my oil cooler with the finned oil lines...
Still cleaning small parts...

http://i132.photobucket.com/albums/q...7072008048.jpg

Finally got the heads and cam housings on:
http://i132.photobucket.com/albums/q...7072008055.jpg

Did you paint the cylinders?

No, they just look dark in colour. They are brand new Mahle's.
I think that my phone camera is to blame....

Finally managed to have a few hours spent on it again...:)

Monted the rockers, adjusted timing, checked piston - valve clearing, mounted valcecovers, and started the excaust work.

964 cams are supposed to have a overlap opening at 1,26 mm (+/- 0,1 mm)
I was pleased to see they fell exactly in the middle of the range.

http://i132.photobucket.com/albums/q...5082008112.jpg

Hydraulic tensioners' chain covers:

http://i132.photobucket.com/albums/q...4082008109.jpg

Valvecovers. Sandblasting sure made a difference.

http://i132.photobucket.com/albums/q...5082008114.jpg

Status quo:
http://i132.photobucket.com/albums/q...5082008115.jpg

Update:

I have completed engine assembly, and attached the gearbox. So by the end of the week, I'll probably have the enging in place.

http://i132.photobucket.com/albums/q...0082008128.jpg

http://i132.photobucket.com/albums/q...1092008137.jpg

http://i132.photobucket.com/albums/q...3092008154.jpg

http://i132.photobucket.com/albums/q...3092008148.jpg

Hello Otto, Looks like you did a great job on your motor.... so congratulations!!! Having to wait for ordered parts can be frustrating. I wanted to make a couple of helpful suggestions to you about the engine. You will find less oil leak problems if you exchange your exhaust valve covers for the Louvered / webbed 930 covers. The web pattern on them prevent them from warping and leaking. The other suggestion would be to place a "pop off" valve inside your injection air box. The is a backfire release valve hinged like a toilet seat / about the size of a cookie that will prevent your air box from getting blown out or cracked. I have my 3.0 out of my Targa this week to find a rattle on the right bank of cylinders. Have you put it in the car yet or is this picture with you and the engine just taken today?? Good luck to you! Josh

http://forums.pelicanparts.com/uploa...1221452018.jpg

Thanks mate!

I have a pop off valve installed, and I'll keep the original covers until I get confirmation of a leak...
I took that picture on friday. Will install it today.
I hope it will be OK...!

Great on the pop off valve. I had a feeling with how meticulous you have been with this project that you had placed one. Also, they have this new valve cover gasket that is reusable. I forget the brand name but I'll try to find and send so if and when. Today I'm digging into my motor. Hopefully it won't be a big $$$ fix. Btw, nice work shop area. Wish I had that much room. I have most of my garage set up for my business to make..... see photo. Have a good install. josh


http://forums.pelicanparts.com/uploa...1221491852.jpg

Haha!!:)
Good luck to you too!

The engine is now in, so hopefully it'll be purring by the end of the week!

Does anyone know if the big positive connection on the starter connects to the battery and to the engine? (My picture does not show this...)

HI Otto
yes the battery and the red from the engine both go to the starter, the red is from the alternator.

regards mike

Thanks, I have it connected now.
So today I have cranked the engine with the starter. It rotated fine, and no oil leaks. Built a preassure of almost 1 bar. :)
Can't wait for tomorrow!!

http://i132.photobucket.com/albums/q...8092008182.jpg

It's alive!!!
Had a ok startup today, but I have a leak in the exhaust. (Easy fix)

The engine sounds bad on the video, but after 15 minutes it sounded almost better than before. (Apart from the exhaust leak)

Video:
http://i132.photobucket.com/albums/q...7/th_Alive.jpg

Congratulations Otto!!! Funny you got an exhaust leak just like I did. Now break that puppy in nicely and enjoy!

Aurel

Thanks Aurel!

Yeah, it's funny huh? I thought of you the moment I heard the leak...

But mine was a much easier fix. I had not put the gasket on properly on one of the cylinders, probably because I did not see it under the heat excanger. (Mounted it upside down, so visibility was not easy...

But now its' alive!!

Some pics:

Reason for leak:
http://i132.photobucket.com/albums/q...0092008184.jpg

Ready for start:
http://i132.photobucket.com/albums/q...0092008185.jpg

After a very needed wash:
http://i132.photobucket.com/albums/q...0092008186.jpg

Have adjusted the timing now, and been on the road for a good couple of hours. Feel so good, I don't think I'm able to put it into words!
I have added a couple of videos...

http://i132.photobucket.com/albums/q...h_CIMG2144.jpg

http://i132.photobucket.com/albums/q...h_CIMG2141.jpg

Congratulations, Otto!

Sounds great, and it FEELS great to have it done, doesn't it?

Thanks!
You bet! -Don't need to call Dr. Feelgood, I got just the cure...:D

Beautiful 911! Sounds awesome, congratulations!! :D

Well done.
You need to replace the nyloc nuts on the exhaust and replace with correct metaloc or plain steel nuts.

Also... Great job here Otto !!! what muffler are you using ?? It sounds like a M&K possibly ??
Please summarize what the final specs of your engine are and what you started with. Any testing as to hp ~ torque it is at now ??
Also, please update every time something arises and/or 1x/month so we all can learn the + and - of things you did.
Again, great job and thanks for sharing your build with us !!!
Bob

Thanks guys!
I started with a stock 3 liter engine, with 8,5:1 copression ratio. My plan was to simply bump up the compression ratio by putting in some 9,5:1 JE pistons. But this was not to be, because my cylinders was alusil alloy. I therefore bought a entire P/C set from Mahle. Still 3 liter, and with 9,8:1 comp ratio.

The engine was fitted with a sport muffler before I started. I don't know the brand, but it's heavy, stainless steel. And it's LOUD. (And yes, I've used the proper hardware for attaching it.);)

This is a summary of what I did, aside from the new P/C set:

-replaced the cams for "964" profile cams (Increase HP)
-replaced cylinderbolts for aftermarket ones
-replaced cat for a pre-muffler from fabspeed (Increase HP)
-mounted an aftermarket oil cooler in front to keep it cool on the track.
-Installed oil preassure fed tensioners.
-Heads done at machine shop.

Of course all gaskets, bearings and also the shafts for the rockers was replaced.

So this is not the cheap way to go... But you can use your cylinders if you have Nicasil alloy. And you can keep the cooling system. (My oil line was old and worn , with some restrictions in the lines)

I have not broken it in yet, but I can allready feel it's "stronger" than before. I do not intend to rev it fully until the next oil change... But I'll update when I get there.

Sadly, the winter is coming soon, so I might not be able to complete the break-in before I have to store it for the winter...

Oh... I dont't know the brand of my muffler, but maybe some of you recognize it?
http://i132.photobucket.com/albums/q...9092008183.jpg

Now, that I'm finished rebuilding, I got bored, and made a video of the project...
Not very good, but a summary of the ordeal..;)

http://www.youtube.com/watch?v=PsYAFJVJtxE

VERY nice clip Otto!

It captures the spirit of doing one of these beasts oneself. Truly a celebration when you get it all back together and it runs.

Muffler looks and sounds very similary to my DP Motorsport item. Agree on heavy, circa 13kg, but the sound is like nothing i've heard from other manufacturers, especially with a bypass pipe

http://lh5.ggpht.com/MrShirishPatel/...gine%20017.jpg

Thanks mate!
That's got to be it! I got it with the car when I bought it. The guy that sold it to me said it costs something like $2500.... (I'm sure he was lying, because he was lying about a lot of stuff. He actually advertized it as a Carrera:rolleyes:)
Anyway, sounds good, and looks good!!!:)

No problem - you should have a small rectangular 'DP' badge on it somewhere.

Oh, he wasn't joking about the price - around 1200Euro!

http://www.dp-motorsport.de/uploads/tx_dpproducts/911_G-Model_equipment.pdf

Got some concrete results now.
I have wondered about the horsepower increase with my mods...
Well I don't know that, but I DO know is this:

0-60 time has improved by 0,4 secs. (From 5,8 to 5,4) -And I guess that's what I was shooting for! (And not bad for a 79 SC)

Hi Otto,

Did you ever get any dyno plots for your rebuild?

Cheers - Gary

No dyno results yet.
The engine is out once again, because I am going to do a job on the tranny.
I'll probably get some dyno results this summer. But maybe, just maybe, I'll install a EFI system first. (Economy will decide) ;)

Gary: Impressive results on your engine , by the way! Are you running it on CIS?

Engine out. -Again:
http://i132.photobucket.com/albums/q...1012009265.jpg

Yes Otto, running on CIS. Be more impressive if I could regain that mid-range torque though ;)

Hey Ottto good job I will start to rebuild my engine on Sat Valt. day wife may piss, just want to know what kind of paint (red) on your engine cover? thanks Steve

Hey there

I used a normal car spraypaint. Seems to do the trick.;)